Belt for use in forming a core for manufacturing an elastomeric tire

ABSTRACT

A belt for incorporation into a core of plies and beads formed on a tire core build mandrel where the core is for encapsulating in an elastomeric material, preferably a polyurethane, in a tire formation process, and which belt is formed from like belt sections laid over one another where the one belt section is rotated one hundred eighty degrees around its longitudinal axis with respect to the other, and the belt sections are individually fitted around a tire core crown and the pair of belt sections ends are off-set from one another and are fitted together into a continuous belt. The belt is a weave of Rayon warp and cotton fill cords or filaments with the Rayon warp cords or filaments having a crossing angle of forty-eight to fifty-two degrees and the Rayon warp and cotton cords or filaments, respectively, have selected diameters, to provide for a separation of the Rayon cords or filaments respectively, in a stack of belt sections.

BACKGROUND OF INVENTION

1. Field of The Invention

This invention pertains to an inelastic belt that is for fitting onto a tire core build mandrel whereon a core of plies and beads has been installed, with the belt formed from a pair of woven belt sections that are installed over one another, with the belt section ends joined together at spaced intervals around the mandrel of approximately one hundred eighty degrees, and with the formed belt providing a desired crossing angle of it inelastic belt warp cords or filaments.

2. Prior Art

The present invention is in a belt for installation over a plies and beads as have been installed onto a tire core build mandrel, with the mandrel mounting the core for fitting into a mold cavity for receiving a flow of an elastomeric material, preferably a polyurethane, encapsulating the core in a formed tire. The belt is formed by overlaying two woven belt sections where each belt section is has a warp of Rayon cords or filaments and includes cotton cords or filaments as the weave fill, and the one belt section has been turned one hundred eighty degrees around its longitudinal axis with respect to the other, and joined belt section ends are spaced approximately one hundred and eighty degrees from one another around the tire core mandrel top or crown surface. The belt sections each have Rayon warp cords that are inelastic and are set at an angle of from twenty four (24) to twenty six (26) degrees to the parallel belt edges, and which cotton fill cords or filaments of the weave aid in providing for holding the Rayon warp cords in position with the warp cords maintained straight and parallel to one another. In practice, two belt sections are laid over one another as the single belt with the Rayon warp cords or filaments having a crossing angle of from forty- eight (48) to fifty- two (52) degrees. In which positioning, the cotton fill cords or filaments aid in maintaining the positioning of the Rayon warp cords or filaments and separate the layers of warp cords or filaments. The belt sections are each formed to have a length to encircle the tire core build mandrel, above a plies sleeve fitted thereon, and the belt section ends each have like opposing angles to fit closely together, with the belt section joined ends spaced approximately one hundred eighty degrees from one another, around the tire core build mandrel top or crown surface. With the single or additional belts encircling the tire core build mandrel, a tire cord is wrapped continuously therearound, completing the assembly of the tire core that can then be fitted into mold cavity to receive a flow of an elastomeric material, preferably a polyurethane material, that encapsulates the core, completing the tire. Which preferred polyurethane material is absorbed into the surfaces of the Rayon warp and cotton cords or filaments and provides a mechanical bond thereto.

A plies sleeve with beads and a Rayon warp cord or filament belt or belts is shown and described in pending patent applications for spin casting and vacuum forming tires of one of the present inventors, as set out in U.S. patent applications entitled: “Improved Method and Apparatus for Forming a Core of Plies, Belts and Beads and for Positioning the Core in a Mold for Forming an Elastomeric Tire”, Ser. No. 10/909,807, filed Aug. 2, 2004; and a “Method and Apparatus for Vacuum Forming an Elastomeric Tire”, Ser. No. 10/936,635, filed Sep. 4, 2004. Which patent applications demonstrate a utilization of a plies sleeve and shows a Rayon cord or filament belt formed on the upper surface of that plies sleeve, across a top or tread area of a tire core build mandrel

A formation of a tire belt is shown in an earlier U.S. patent application by one of the present inventors entitled, “Method and Apparatus for Forming a Core of Plies, Belts and Beads and for Positioning the Core in a Mold for Forming an Elastomeric Tire”, Ser. No. 10/909,807, filed Aug. 2, 2004. In which tire belt formation, a Rayon cord or filament is laced back and forth between spaced offset teeth of gear plates, with the cord forming an angle of approximately twenty four (24) degrees to the belt sides. In which belt formation, sections of cotton matt material were fitted between the plies surface, and between belt sections and belts and a final section of thin cotton material was installed onto of a final belt in forming the tire core. Whereas, with the invention, a need for installing sections of cotton material, or like separators between the plies, belt sections and belts is not needed.

SUMMARY OF THE INVENTION

It is a principal object of the present invention to provide a tire belt formed from two belt sections that are stacked to form a single belt after one of the belt sections has been rotated one hundred eighty (180) around its longitudinal axis to the other, and the belt section ends are joined across from one another, forming a continuous belt around a tire core build mandrel top or crown surface that a tire plies has been mounted on.

Another object of the present invention is to provide a tire belt that is a weave of Rayon warp cords or filaments and cotton fill cords or filaments where the rectangular weave is held together by the cotton fill cords or filaments when belt sections are cut on a bias beneath an adhesive layer where the warp cords or filaments are at angles of from twenty four (24) to twenty six (26) degrees to the belt section cut edges, and the distance across the belt section is that of the width of a tire core build mandrel top or crown surface.

Another object of the present invention is to provide a tire belt formed from a pair of belt sections where the one belt section is rotated one hundred eighty (180) degrees around its longitudinal axis the other such that the warp cord or filament angle of the two belt sections combine to a warp cord or filament crossing angle of from forty eight (48) to fifty two (52) degrees.

Another object of the present invention is to provide a tire belt that does not require a use of spacing layers between the belt sections, belts or above or below a tire belt.

Still another object of the present invention is to provide a tire belt formed from a pair of belt sections that are cut or otherwise formed from sections of a weave of Rayon warp and cotton cords or filaments, where the cuts are treated with an adhesive layer and are on a bias angle to the weave such that the warp cords or filaments are at an angle of from twenty four (24) to twenty six (26) degrees to the belt section sides.

Still another object of the present invention is to provide a tire belt formed from a pair of like belt sections where the one belt section is rotated one hundred eighty (180) degrees about its longitudinal axis to the other belt section, where the respective Rayon warp and cotton fill cords or filaments each have a diameter that is selected to allow for a desired spacing distance between the Rayon warp cords or filaments when the belt sections are stacked, and between a plies layer below the belt and between the belt top surface and a wound layer of tire cord.

Still another object of the present invention is to provide a tire belt formed from belt sections cut from a woven section with the cut edges receiving an adhesive, such as a starch based adhesive, applied thereto, with the belt section to have a length to close around a mandrel top or crown surface, above a plies layer, and where the belt section ends are formed with like opposing angles to fit together, forming a continuous belt section, with two overlaying belt sections having their contacting ends spaced approximately one hundred eighty degrees apart around the mandrel top or crown surface, forming a single belt, and including an arrangement for holding which belt section ends together.

Still another object of the present invention is to provide a belt system where a belt is formed by overlaying two like belt sections, where the one belt section has been rotated one hundred eighty degrees relative to the other around the belt section longitudinal axis, and the warp and fill cords or filaments that form the belt section weave are Rayon and cotton cords or filaments, respectively, that provide for a strong surface bonding with a polyurethane mixture as is preferably used to form a tire containing the belt, providing a mechanical lock between the cords or filaments surfaces and the cured polyurethane material.

The present invention is in a belt system for installation around a top or crown surface of a tire core build mandrel that a core of plies and beads have been mounted on, forming a core of plies beads and belts that is encapsulated in an elastomeric tire formed by casting, molding, vacuum forming or like methods. The belt or belts of the invention are fitted and maintained around the top or crown surface of the tire core build mandrel, and receives a winding of tire cord wound around the mounted belt as a final step informing a tire core that is for mounting in a mold wherein an elastomeric material, preferably a polyurethane material, is introduced during the tire molding, casting or vacuum forming process. The belt sections of the invention are each formed from a section of woven material that has a selected width to allow cutting or otherwise forming individual belt sections where the width across each belt section is the width of the top or crown of the tire core build mandrel with a plies sleeve fitted thereon. Additionally, the belt section is cut or otherwise formed from the section of woven material to where its warp cords or filaments present like angles of twenty four (24) to twenty six (26) degrees to the belt section sides, and with the fill cords or filaments assisting in maintaining the warp cords or filaments together after the section of woven material is cut or formed into belt section. Additionally, the cut belt section edges are preferably treated with an application of an adhesive to eliminate a possibility of the belt section cut section edges unraveling. Each of which belt sections is formed to have a length to fit around the tire core build mandrel mounting the plies sleeve, and the belt section ends are formed to have like opposing angles that, when fitted and maintained together, form a continuous belt that encircles the tire core build mandrel top or crown surface, above a plies sleeve. A second belt section that is like the first belt section but may be slightly longer and narrower, and is rotated one hundred eighty (180) degrees around its longitudinal axis, is installed on top of the first belt section, forming a belt that has a crossing angle of the warp cords of filaments of from forty eight (48) to fifty two (52) degrees.

The invention provides woven belt sections for assembly in pairs into a continuous belt that fits snugly around a top or crown surface of a tire core build mandrel whereon a plies sleeve has been mounted. The individual belt sections are formed from a weave of Rayon warp and cotton cords or filaments where the Rayon warp cords or filaments preferably have a diameter of from point zero two five (0.025) to zero three five (0.0350 inches and the cotton fill cords preferably have a diameter of from point zero zero eight (0.008) to point zero two zero (0.020) inches, and the preferred weave has a weave density of from ten (10) to eighteen (18) Rayon warp cords per inch and four (4) to fourteen (14) cotton fill cords per inch. In practice, a weave known as a single layer plain weave is preferred to form the woven section where the cotton cords of filaments and will aid in maintaining the Rayon warp cords or filaments in a straight parallel attitude to one another and at a desired spacing distance when belts sections are stacked. Before which belt section stacking, and preferably before or during belt section cutting, the belt section sides are stabilized, as by application of an adhesive, such as a starch based adhesive, that is applied there along, holding the Rayon warp cords or filaments together, with the Rayon warp cords maintained at an angle of from twenty four (24) to twenty six (26) degrees to the belt sections sides.

In practice the selection of the particularly of the Rayon warp and cotton fill cords or filaments, and their preferred arrangement in cords or filaments per inch, provides finished belt sections that, when stacked together and onto a plies sleeve surface, create a required spacing distance between the Rayon warp cords or filaments in the belt section and between the belt sections to allow for a free passage of a polyurethane material flow therethrough, encasing the tire core, in the tire formation process. Accordingly, where earlier arrangements of plies sleeve, belts and belt cord wrap have required the inclusion of spacing layers, such as sections of thin cotton material, a spacing layer or layers are not required with the belt arrangement of the present invention. With the present invention, the tire core assembly is simplified in that, to form a belt, a pair of belt sections are individually positioned over one another without a need for a separate spacing layer arranged therebetween, and are positioned around a tire core build mandrel top or tread surface, directly onto a plies sleeve earlier fitted thereto. The belt sections ends are fitted and maintained together, with the Rayon warp filaments essential straight and tight, and spacing is provided between the belt sections. Thereafter, a second belt can be fitted over a first, as needed, and the assembly is then wound with a continuous tire cord, completing a formation of a tire core for installation in a mold to form an elastomeric tire.

DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangement of parts, used to form the belt of the invention that is herein shown as a preferred embodiment and will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof:

FIG. 1 shows a top plan view of a woven section of material that is a weave of Rayon warp and cotton fill cords or filaments and is shown as being cut or separated with a round blade that travels along broken lines A, behind an application of a layer of an adhesive, shown as a brush, that is in contact with the belt sections , with the formed belt sections ends at the sides of the woven section shown as having like opposing angles with each belt section for joining into a continuous belts section;

FIG. 2 shows an enlarged side elevation view of a section of a belt section showing the separate parallel Rayon warp cords or filaments and a continuous cotton fill cords or filaments of the invention as having received an application of an adhesive, as shown in FIG. 1;

FIG. 3 is an end elevation view of the enlarged side elevation view of the section of a belt section shown in FIG. 2:

FIG. 4 is a side elevation perspective view of a pair of belt sections of FIG. 1, with the one belt section shown positioned beneath a tire core build mandrel that is shown in broken lines, with the one belt section for positioning over the other and has been rotated one hundred eighty (180) degrees along its longitudinal axis, with the belt section shown aligned for bending around a top or crown surface of the tire core build mandrel, and showing connecting pads that are each aligned over one belt- section end for connecting to the other belt section end forming continuous belt sections, forming a continuous belt, where the connected belt section ends are on opposite sides of the tire core build mandrel;

FIG. 5, shows the tire core build mandrel as was illustrated in broken lines of FIG. 4, that a plies sleeve and beads have been fitted to, and shows a top of the pair of belt sections of FIG. 4 as having been connected at its ends, with the two belt sections forming a continuous belt;

FIG. 5A shows an enlarged sectional view taken within the curved line 5A of FIG. 5, showing the crossing angle of the Rayon cords or filaments as being from forty eight (48) to fifty two (52) degrees;

FIG. 6 shows an exploded end side elevation perspective view of a section of a tire core that includes a stack of a pair of belt sections of the invention that encircles the tire core build mandrel of FIG. 5, and is maintained above the plies; and

FIG. 7 shows a profile sectional view of a section of and elastomeric tire that has been cast, molded, vacuum formed, or otherwise fabricated to contain the tire core of FIG. 6.

DETAILED DESCRIPTION

The invention is in a belt 24 that, as shown in FIG. 5, is installed onto a top or crown 41 of a tire core build mandrel 40. The belt 24 is fabricated from a pair of like belt sections 21 that are each a weave of Rayon and cotton warp and fill cords 25 and 26, respectively, as shown in FIG. 5A, with the belts section 21, as shown in FIG. 1, cut or formed from a section of the woven material 20. The belt sections 21 are cut, or otherwise formed, on a bias across the woven material 20, as illustrated by broken lines A, and, during, before, or after which cutting, an adhesive is applied along the cut, broken lines A, stabilizing the weave. Which application of an adhesive is illustrated as a brush 28 shown ahead of a cutting blade 29, shown as a disk, that is turned to travel along the broken lines A, cleanly cutting the woven material 20 into belt sections 21. It should be understood, that the adhesive layer 28 a is preferably a starch based adhesive that is compatible with the Rayon and cotton cords or filaments, and with the polyurethane material as used to cast a tire containing the tire core, and which adhesive layer 28 a may be applied before the woven material 29 is cut or during or after cutting, within the scope of this disclosure, for stabilizing the belt section 21 edges.

The width of the woven material 20 is selected to allow for the belt sections 21 to be cut on a bias angle of from twenty four (24) to twenty six (26) degrees to the side of the woven material 20, and to a width and length to fit across and around a top or crown 41 of a tire core build mandrel 40, that is illustrated in broken lines in FIG. 4. Also, the belt sections 21 may be of slightly different length and width to compensate for the one belt section being fitted over the other, within the scope of this disclosure. Which belt sections 21 have ends 22 a and 22 b that have like opposing angles to fit together into continuous belt 24, where the belt section warp and fill cords or filaments, 25 and 26 respectively, at the ends 22 a and 22 b, will align. To maintain which alignment, as illustrated in FIGS. 4 and 5, joining sections of material 27 can be installed across the belt section ends 22 a and 22 b junctions. Which sections of material 27 are preferably thin sections of a cotton material where the surfaces of the cotton filaments making up the section of material 27 will grip the surfaces of the cotton fill cords or filaments 26 when the sections of material are pressed into the belt section 21 ends 22 a and 22 b. The belt section ends 22 a and 22 b are thereby coupled, providing a coupling that will resist separation with the addition of a second belt or belts 24 and a winding of the belted tire core build mandrel with tire cord. While such section of material 27, formed from a thin cotton section of material, can be used as described for holding abutting edges of the belt section ends 22 a and 22 b, it should be understood that other coupling arrangement could be so used, such as a tape having an adhesive on one surface, within the scope of this disclosure.

As shown in FIG. 4, to form the belt 24, a pair of belt sections 21 are stacked over one another with the one belt section 21 rotated one hundred eighty (180) degrees along its longitudinal axis to the other and each belt section 21, in turn, is bent around the top or crown surface 41 of the tire core build mandrel, and the belt section ends 22 a and 22 b are fitted together and receive the section of material 27 pressed onto which junction, forming a continuous belt section 21. In which belt section mounting, as illustrated in FIG. 4, the ends of each belt section are spaces approximately an equal distance around the tire core build mandrel 41 from one anther. Whereafter, the second belt section 21 is installed over the first, forming the belt 24, as shown in FIG. 5. In which belt section mounting, as illustrated in FIG. 4, the ends 22 a and 22 b of each belt section 11 are preferably spaces approximately an equal distance around the tire core build mandrel 41 from one another.

The belt 24, as shown in FIG. 5A, has Rayon warp cords or filaments 25 that cross at a crossing angle of from forty eight (48) to fifty two (52) degrees. FIGS. 2 and 3 show the cotton fill cords or filaments 26 as providing for lateral separation of the Rayon cords or filaments 25. Additionally, which cotton fill cords or filaments, as shown in FIG. 5A, provide also for vertical separation of the Rayon warp cords or filaments 25 in the one belt section 21 from those in the other belt section 21. So arranged, the cotton fill cords or filaments 26 provide, along with the application of an adhesive layer 28 a, as illustrated by brush 28 in FIG. 1, along the belt section 21 edges, for maintaining a desired spacing distance between and holding the Rayon warp cords or filaments 25 straight in the formation of the belt 24. Further, in practice, a weave of the invention incorporates Rayon cords or filaments 26 having a diameter of approximately point zero three zero (0.030) inches, and cotton fill cords 26 having a diameter of approximately point zero zero eight to point zero one zero (0.008/0.010) inches. It should, however, be understood the respective Rayon warp and cotton fill cords or filaments can be from (0.025) to (0.035) inches and (0.008) to (0.020) inches, respectively, within the scope of this disclosure. In practice a weave density of fourteen (14) of the Rayon warp cords or filaments per inch and ten (10) to fifteen (15) of the cotton fill cords or filaments per inch have been used in weaving the section of woven material 20 of FIG. 1. It should, however, be understood that the woven material 20 can contain from ten (10) to eighteen (18) Rayon warp cords or filaments per inch, and four (4) to fourteen (14) per inch of the cotton fill cords or filaments, within the scope of this disclosure. Which diameter of Rayon warp and cotton fill cords or filaments 25 and 26, respectively, at their preferred density, produces a section of woven material 20 that can be cut along the broken lines A, as shown in FIG. 1, into the belt sections 21 and, with an application of the adhesive to the best section 21 cut edges, that is preferably starch based, the belt section edges will each retain their dimensional integrity after cutting. The belt sections are then wrapped, as shown by arrows B in FIG. 4, around the mandrel 40 top or crown surface 41 and the junctions of the belt sections ends 22 a and 22 b are maintained by the application of sections of cotton material 26, or the like, applied thereover, and are located opposite sides of the mandrel 40 top or crown surface, forming a continuous belt 26, as shown in FIG. 5.

FIG. 6 shows an exploded view of a tire core 50 having a separator layer 53 between a tire core build mandrel 40, shown in broken lines in FIG. 4, and in FIG. 5, whereon a plies sleeve 51 is fitted whose ends 51 a have been wrapped around beads 52, and incorporates belts 24 aligned over the plies sleeve. Which tire core 50 has been removed off from the tire core build mandrel 40 of FIGS. 4 and 5. FIG. 6 illustrates that, with the belt or belts 24, assembled as set out above, separator layers, such as thin sections of cotton matt material as have been used in the core systems set out in the Prior Art cited above, are not required. Rather, the utilization of cotton cords as the fill cords or filaments 26 and their density in the weave of the woven material 20 provides for both maintaining the positioning of the Rayon warp cords or filaments 25 and for their lateral separation in the weave, within the stack of the belt sections 21, and between the plies 51, belt or belts 24 and a tire cord wrap 58. With the installation of the tire cord wrap 58, the tire core 50, that includes one or more belts 24, is ready for installation into a cavity of a mold as is used to form an elastomeric tire.

The elastomeric tire incorporating the invention is preferably formed from a polyurethane material in a molding, casting, vacuum forming or other process, and is shown as tire 65 in FIG. 7. Which tire 65 shows the single belt 24 formed by overlaying two belt sections 21 that are each a weave of individual Rayon warp cords or filaments 25 and a continuous cotton fill cord or filament 26, and shows the polyurethane material as having flowed through and saturated the tire core, providing a mechanical lock to the plies sleeve material, belt or belt material, and beads, forming a homogeneous finished tire 65 that, additional to the tire core 50, includes the polyurethane surface 65 wherein a tread 66 is formed around the top or crown. Which mechanical lock of the polyurethane material to the belt 24 warp and fill cords 25 and 26 is a result of a use of Rayon as the warp cords or filaments 25 and cotton as the fill cords or filaments 26 where the cords or filaments surfaces tend to absorb the selected polyurethane material and provide a very strong mechanical bond therebetween.

While a preferred embodiment of our invention in a tire belt for use in forming a tire core for casting, molding, vacuum forming or otherwise manufacturing a transport tire around a core, has been shown and described herein, it should be understood that variations and changes are possible to belt and belt sections and the belt manufacture on a tire core and the core's use in the formation of a tire, as well as the materials used in tire fabrication, without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims we regard as our invention. 

1. A belt for use in a formation of a tire core that also includes plies and beads where the core is for installation in a mold for forming a polyurethane tire comprising, a pair of identical belt sections for positioning over one another after one belt section has been turned one hundred eighty degrees about a longitudinal axis with respect to the other, and each said belt section is a weave of Rayon warp cords or filaments and cotton fill cords or filaments, where said Rayon warp cords or filaments are essentially parallel and form an angle of from twenty-four to twenty-six degrees to parallel sides of said belt section, and which said belt section has a width to extend across a top or crown surface of a tire core build mandrel, a length to extend around said tire core build mandrel, and with said belt section ends for fitting together.
 2. The belt for use in a formation of a tire core as recited in claim 1, wherein the belt section ends of each of the two belt sections are positioned on opposite sides of a tire core mandrel top surface whereon the core is being formed.
 3. The belt for use in a formation of a tire core as recited in claim 1, wherein the stack of belt sections Rayon warp cords or filaments have crossing angles of from forty eight (48) to fifty two (52) degrees to one another.
 4. The belt for use in a formation of a tire core as recited in claim 1 wherein the belt sections are formed from a woven section of material that is cut at spaced intervals and at an angle of from twenty-four (24) to twenty-six (26) degrees to parallel sides of said woven section of material.
 5. The belt for use in a formation of a tire core as recited in claim 4, wherein the diameter of the Rayon warp cords or filaments used for weaving the section of material is between point zero two five inches and point zero three five inches.
 6. The belt for use in a formation of a tire core as recited in claim 4, wherein the diameter of the cotton fill cords or filaments for use in weaving the section of material is between point zero zero eight and point zero two zero inches.
 7. The belt for use in a formation of a tire core as recited in claim 1, wherein the weave density of the belt sections is from ten to eighteen filaments per inch of the Rayon warp cords or filaments and from four to fourteen filaments per inch of the cotton fill cords or filaments.
 8. The belt for use in a formation of a tire core as recited in claim 1, wherein the belt section ends are maintained together by an application of a thin section of cotton material, spanning the belt section ends junctions.
 9. The belt for use in a formation of a tire core as recited in claim 1, further including, a layer of an polyurethane compatible adhesive applied along the opposite belt sides.
 10. The belt for use in a formation of a tire core as recited in claim 9, wherein the adhesive is starch based. 